Materials management system and method

ABSTRACT

A materials management system ( 10 ) comprises a materials database ( 12 ) for storing information relating to the nature identity and location of each item of material on a site. A mobile data processing device ( 14 ) is provided, having a data scanner ( 16 ) for scanning machine-readable identification information provided in an identification tag attached to an item of material. A GPS receiver ( 18 ) is operatively connected to the mobile data processing device ( 12 ) for obtaining the GPS coordinates of the item of material. The mobile data processing device ( 14 ) transmits the GPS coordinates and the identification information to the materials database ( 12 ) so that the location of each item of material on site can be tracked. The materials database ( 12 ) can be accessed online from anywhere in the world via satellite link ( 20 ) (or internet) using any suitable desktop personal computer ( 22 ). The materials management system has particular application to a construction site, and sites where intrinsically safe systems are required.

This application is the U.S. national phase of International ApplicationNo. PCT/AU2009/000491, filed 21 Apr. 2009, which designated the U.S. andclaims priority to Australian Application No(s). 2008901970, filed 21Apr. 2008 and 2008904957, filed 23 Sep. 2008, the entire contents ofeach of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a system and method of materialsmanagement on a site and relates particularly, though not exclusively tosuch a system and method for managing materials for a construction site(onsite and offsite).

BACKGROUND TO THE INVENTION

In large building projects a failure to keep track of constructionmaterials is a major contributor to cost-overruns and constructiondelays. Construction materials may be delivered on time to the site, butwhen the time comes to install the materials it can sometimes bedifficult to locate the materials in the lay-down yard. The time takentrying to locate the materials consumes precious labour time, and in aworse case scenario a failure to locate the materials requiringre-ordering and delivery adds further unnecessary costs and delays tocompletion of the project. Therefore it is desirable to have a systemand method of managing all phases of the material handling process, fromprocurement, expedition and transport through to onsite arrival, storageand installation.

The present invention was developed with a view to providing a systemand method of materials management which facilitates tracking thelocation of each item of material offsite and on site from the time ofarrival to installation. Although the invention will be described withparticular reference to construction sites, it will be appreciated thatthe invention has wider application to tracking the location of items ofmaterial on other sites.

References to prior art in this specification are provided forillustrative purposes only and are not to be taken as an admission thatsuch prior art is part of the common general knowledge in Australia orelsewhere.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided amaterials management system for a site, the system comprising:

a materials database for storing information relating to the nature,identity and location of each item of material on a site;

a software module for colour-coding each item on the site in a 3D modelof the site, the software module monitoring the database and, as astatus of an item changes in the database, changing the colour of theitem in the 3D model to give an immediate visual indication of thecurrent status of the item; and,

a mobile data processing device having a data scanner for scanningmachine-readable information, including identification information,provided in an identification tag attached to an item of material, and aGPS receiver operatively connected to the mobile data processing devicefor obtaining the GPS coordinates of the item, the mobile dataprocessing device transmitting the GPS coordinates and theidentification information to the materials database whereby, in use,the status of each item of material on site can be tracked.

In one embodiment the mobile data processing device is a handhelddevice. Preferably the mobile data processing device is a handheldpersonal digital assistant (PDA). Advantageously the data scannerprovided in connection with the mobile data processing device is abarcode scanner. Alternatively the data scanner provided in connectionwith the mobile data processing device is an RFID tag scanner.

In one embodiment the mobile data processing device is an intrinsicallysafe handheld device. Preferably the mobile data processing device is ahandheld personal digital assistant (PDA). Advantageously the datascanner provided in connection with the mobile data processing device isan intrinsically safe barcode scanner. Alternatively the data scannerprovided in connection with the mobile data processing device is anintrinsically safe RFID tag scanner.

In one embodiment the GPS receiver is operatively connected to themobile data processing device by means of a wireless communicationslink. In an alternative embodiment the GPS receiver is integrated andhardwired into the mobile data processing device.

Advantageously the data scanner provided in connection with the mobiledata processing device is capable of scanning additionalmachine-readable information provided in the identification tag attachedto an item of material, such additional machine-readable informationrelating to the ongoing maintenance of the item.

Preferably the system further comprises one or more sensing devicesprovided in connection with the item of material for sensing a conditionof the item, the sensing device being electronically coupled to theidentification tag, wherein information relating to the condition of theitem can be stored in the identification tag for maintenance purposes.In one embodiment the identification tag is an RFID tag.

Preferably the system further comprises a document control database inwhich identification information for any documents associated with anitem recorded in the materials database is stored.

Advantageously the system further comprises a progress control databasein which the progress of each item in the materials database iscontrolled according to applicable “Rules of Credit.” Typicallyelectronic tick sheets which are linked to the materials database may beused in this regard.

According to another aspect of the present invention there is provided amethod of managing materials on a site, the method comprising the stepsof:

applying an identification tag to each item of material on a site, thetag containing machine-readable information, including identificationinformation identifying the item of material;

providing a materials database for storing information relating to thenature, identity and location of each item of material on a site;

scanning an identification tag attached to an item of material on siteto read the machine-readable information;

obtaining the current GPS coordinates of the item;

transmitting the current GPS coordinates and the identificationinformation to the materials database;

updating the status of the item in the database based on the current GPScoordinates and identification information;

providing a 3D model of the site; and,

changing the colour of the item shown in the 3D model based on thecurrent status of the item according to the update information in thematerials database whereby, in use, the status of each item of materialon site can be tracked.

Preferably the method comprises the further steps of:

storing additional machine-readable information in the identificationtag, including information relating to the ongoing maintenance of theitem in the identification tag;

transmitting the additional information to the materials database; and,

updating a maintenance log for the item in the database whereby, in use,the ongoing maintenance of each item of material on site can be tracked.

Advantageously the additional information stored in the identificationtag also includes information relating to the progress of the item inthe various stages of construction. Preferably the information relatingto the progress of the item is transmitted to and recorded in a progresscontrol database, in which the progress of each item in the materialsdatabase is controlled according to applicable “Rules of Credit.”

According to a still further aspect of the present invention there isprovided a method of updating a materials database for a materialsmanagement system, the method comprising the steps of:

retrieving a material item record stored in the materials database uponreceiving identification information scanned from an identification tagattached to an item of material;

generating and displaying an update screen for the material item recordwherein, in use, an operator can input update information for thematerial item record, including the current GPS coordinates of the itemof material;

updating the material item record in the materials database with theupdate information;

providing a 3D model of a site where the item of material is to beinstalled; and,

changing the colour of the item shown in the 3D model based on thecurrent status of the item according to the update information in theupdated material item record of the materials database.

Preferably the method of updating a materials database furthercomprises, in the case where a material item entry cannot be retrievedfrom the materials database based on the scanned identificationinformation, the steps of:

-   -   generating and displaying a search screen wherein, is use, an        operator can specify a Mark No for the material item;    -   searching the materials database for all items having the        specified Mark No;    -   displaying the search list for all items with the specified Mark        No wherein, in use, an operator can select an item from the        search list; and,    -   retrieving a material item record stored in the materials        database corresponding to the item selected by the operator.

Preferably the method of updating a materials database furthercomprises, in the case where no items having the specified Mark No canbe retrieved from the materials database or where none of the items withthe specified Mark No corresponds to the material item, the steps of:

generating and displaying a screen that enables the operator to create anew record in the materials database for the specified Mark No ormaterial item; and,

storing the new record in the materials database.

Advantageously the method of updating a materials database furthercomprises the steps of:

providing an associated progress control database;

creating suitable “Rules of Credit” for controlling the progress of anitem of material in the progress control database;

assigning a “Rule of Credit” to each item in the materials database; and

progressing each item in the progress control database according to theapplicable “Rule of Credit.”

According to a further aspect of the present invention there is provideda materials management system for a construction site, the systemcomprising:

a materials database for storing information relating to the nature,identity and location of each item of material on the construction site;

a software module for colour-coding each item on the site in a 3D modelof the construction site, the software module monitoring the databaseand, as a status of an item changes in the database, changing the colourof the item in the 3D model to give an immediate visual indication ofthe current status of the item; and,

a mobile data processing device having a data scanner for scanningmachine-readable information, including identification information,provided in an identification tag attached to an item of material, and aGPS receiver operatively connected to the mobile data processing devicefor obtaining the GPS coordinates of the item, the mobile dataprocessing device transmitting the GPS coordinates and theidentification information to the materials database whereby, in use,the status of each item of material on the construction site can betracked.

In one embodiment the mobile data processing device is a handhelddevice. Preferably the mobile data processing device is a handheldpersonal digital assistant (PDA). Advantageously the data scannerprovided in connection with the mobile data processing device is abarcode scanner. Alternatively the data scanner provided in connectionwith the mobile data processing device is an RFID tag scanner.

Throughout the specification, unless the context requires otherwise, theword “comprise” or variations such as “comprises” or “comprising”, willbe understood to imply the inclusion of a stated integer or group ofintegers but not the exclusion of any other integer or group ofintegers. Likewise the word “preferably” or variations such as“preferred”, will be understood to imply that a stated integer or groupof integers is desirable but not essential to the working of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature of the invention will be better understood from the followingdetailed description of several specific embodiments of system andmethod of materials management, given by way of example only, withreference to the accompanying drawings, in which:

FIG. 1 illustrates a preferred embodiment of a system for managingmaterials on a site;

FIG. 2 is a flow chart illustrating a preferred embodiment of a methodof managing materials on site employing the system of FIG. 1;

FIG. 3 is a flow chart illustrating a preferred embodiment of theprocess of updating information in a materials database provided in thesystem of FIG. 1;

FIG. 4( a), (b), (c), (d) and (e) are screen shots of a various screenstypically displayed on a preferred embodiment of a mobile dataprocessing device employed in the system of FIG. 1;

FIG. 5 (a) is a flow chart illustrating a preferred method of updating amaterials database using 3D Software;

FIG. 5 (b) is an example of a 3D model of a construction site showingvarious items colour-coded according to their current status in thematerials database provided in the system of FIG. 1;

FIG. 6 illustrates schematically a preferred embodiment of a documentcontrol database associated with the system of FIG. 1;

FIG. 7 is a flow chart illustrating the process of updating a progresscontrol database associated with the system of FIG. 1;

FIG. 8 is a screen shot of a preferred embodiment of a progress controlscreen employed in connection with the progress control database of FIG.7;

FIG. 9 is a flow chart illustrating a process flow (batch mode) showinghow a user can update the information on various devices and can thenupload the information using a docking system; and

FIG. 10 is a flow chart illustrating a process flow (safe mode).

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A preferred embodiment of materials management system 10 in accordancewith the invention, as illustrated in FIG. 1, comprises a materialsdatabase 12 for storing information relating to the nature, identity andlocation of each item of material on a site. The database 12 ispreferably an SQL Server database system hosted on a web serveroperating with a Microsoft Windows operating system platform using the.NET Framework. SQL Server is a relational database management system(RDBMS) produced by Microsoft (Registered Trade Mark). Its primary querylanguage is Transact-SQL, an implementation of the ANSI/ISO standardStructured Query Language (SQL). SQL Server allows multiple clients touse the same database concurrently. As such, it is able to controlconcurrent access to shared data; it will ensure data integrity whenmultiple clients update the same data, or clients attempt to read datathat is in the process of being changed by another client.

The system preferably further comprises a mobile data processing device14 having a data scanner 16 for scanning machine-readable identificationinformation provided in an identification tag attached to an item ofmaterial. In this embodiment the identification tag is amachine-readable barcode printed on a label which is attached to theitem of material. However any other suitable identification tag, withmachine-readable identification information, may be employed, forexample, a Radio Frequency Identification (RFID) tag. In the illustratedembodiment the mobile data processing device 14 is a Symbol MC9090-Shandheld mobile computer (PDA) manufactured by Motorola. The SymbolMC9090-S PDA uses the Microsoft Windows Mobile operating system andincorporates omnidirectional 1D and 2D image scanning data capturetechnology 16 suitable for reading barcode labels. The MC9090-S PDA 14is configured as a client of the SQL Server database system 12 andcommunicates with the database 12 using web services provided via mobiletelephone coverage.

A GPS receiver 18 is operatively connected to the mobile data processingdevice 12 for obtaining the GPS coordinates of the item of material. Inthis embodiment the GPS receiver is a Bluetooth GPS receivermanufactured by Linkspoint which can be connected to anyBluetooth-enabled mobile device and is capable of providing the globalpositioning coordinates of a specific location with an accuracy ofwithin 3-5 meters. The Linkspoint Bluetooth GPS receiver supports theWindows Mobile operating system and can be operatively connected to theMC9090-S 14 using a Bluetooth wireless link. In an alternativeembodiment (not illustrated) the GPS receiver chip set is integratedinto the mobile data processing device 14 and is operatively connectedthereto by hardwiring.

Being a web-based system, the materials database 12 can be accessedonline from anywhere in the world via satellite link 20 (or internet)using any suitable desktop personal computer 22 or laptop personalcomputer (not shown). The personal computer is typically connected tothe web using a broadband connection via a router 24 and enables theuser to access various reporting functions provided with the materialsdatabase software to analyse, manage and document construction progress.

A preferred method of managing materials on a construction site will nowbe described with reference to FIG. 2. When an item of constructionmaterial, for example, a steel beam, first arrives on site, a barcodelabel is applied to the item, indicated as step 100. The materials mayalready have been entered into the materials database, for example, atthe time of procurement, and each type of material given a unique MarkNo. If there is more than item of the same type of material, each itemreceives a unique barcode, even though they may all have the same MarkNo. The bar-coded items are then scanned using the PDA 14, indicated asstep 102.

The PDA 14 then communicates with the materials database 12 and checksif this bar-coded item already appears in the database 12. This query isindicated in FIG. 2 as step 104. If the item does not appear in thedatabase a new entry can be made in the database 12 via the PDA 14,indicated as step 106. If the item is found in the database 12, the PDA14 then obtains the GPS coordinates from the associated GPS receiver 18,indicated as step 108. When the longitudinal and latitudinal GPScoordinates are obtained, this information is then transmitted to thematerials database 12, indicated as step 110, and the materials database12 is updated with the new coordinates, indicated as step 112. Otherinformation relating to the item may be updated in the database 12 viathe PDA 14, for example, if the item has been installed the date ofinstallation.

A preferred method of updating an item or creating a new item in thedatabase 12 using the PDA 12 will now be described in more detail withreference to FIGS. 3 and 4. The user scans the barcode on an item usingthe data scanner 16 provided in connection with the PDA 14, indicated asstep 114 in FIG. 3. If for some reason the barcode label will not scan,the user can also enter the barcode No. manually via the PDA keypad.This query is indicated as step 116 in FIG. 3. If the barcode is foundand it's a good read then the PDA displays the Update Item Screen,indicated as step 124.

If the barcode is not found (bad read) then the PDA 14 displays theSearch Screen, indicated as step 118 in FIG. 3. A sample screen shot ofthe Search Screen is shown in FIG. 4( a). When the “Search” button ispressed, the PDA 14 sends a query to the database 12 to find thematching Mark Nos. This query is indicated as step 119 FIG. 3. If nomatching Mark Nos are found, the system displays the Create NewEquipment/Mark No Screen, indicated as step 126 in FIG. 3. If anymatching Mark Nos are found, the PDA then displays the search list forthe matching Mark Nos on the PDA 14, indicated as step 120 in FIG. 3. Ascreen shot of a typical search list in a “Select Mark No Screen” fromwhich a user can select the desired Mark No is shown in FIG. 4( b).

The user looks for the desired Equipment/Mark No on the screen andselects the desired Mark No (e.g. by clicking on the Mark No on thescreen). The system then queries the database 12 for all the itemsrelating to that Mark No, indicated as step 121 in FIG. 3. If no itemsare found, the system displays the Create New Equipment/Mark No Screen,indicated as step 126 in FIG. 3. If any items relating to that Mark Noare found, the list of items is displayed on the PDA 14, indicated asstep 122 in FIG. 3. A screen shot of a typical search list in a “SelectItem Screen” from which a user can select the desired item is shown inFIG. 4( c).

When the user selects the desired item from the list, the system thendisplays the Update Item Screen, indicated as step 124 in FIG. 3. Ascreen shot of a typical Update Item Screen is shown in FIG. 4( d). Thefollowing items will populate according to the information in thedatabase for that item:

-   -   1. Mark No    -   2. Short Description of item    -   3. Barcode No    -   4. Status    -   5. Wt (KG)    -   6. Received Date    -   7. Issue Date    -   8. Install Date    -   9. GRL/Location    -   10. GPS Longitudinal coordinate    -   11. GPS Latitudinal coordinate

The following fields are read only: Mark No, Short Desc, Status, and Wt(KG) The following fields are read and write: Barcode, Received Date,Issue Date, Install Date, GRL/Location, GPS Long, GPS Lat.

The user can then update the required fields via the PDA 14 and theupdated information is then transmitted to the materials database 12.For example the No printed on the barcode label can be entered into theBarcode field. When the “Save” button is clicked the item isautomatically undated in the database 12. In this way the location,status and physical attributes of each item of construction material onthe site can be updated.

In order to create a new entry in the database 12 for a new item ofEquipment/Mark No, the Create New Equipment/Mark No Screen is displayed,indicated as step 126 in FIG. 3. A screen shot of a typical Create NewEquipment/Mark No Screen is shown in FIG. 4( e). This screen displaysthe Equipment Fields from an Equipment table provided in the database12. The user enters the following fields to create new items

-   -   1. Mark No    -   2. Short Desc    -   3. Category (Drop Down)    -   4. Wt (Kg)    -   5. Qty (integer)

The functionality of the buttons provided on the PDA screen is asfollows:

Create Button: when the Create button is pressed

-   -   1) the system should add the Mark No Details in the Equipment        table and    -   2) the number of items should be created for that Mark No in the        item table according to the Qty.        -   a. E.g. if user enters Qty=10 for mark no SB200-01-1001-NP            it should create 10 items associated to Mark No            SB200-01-1001-NP    -   Mark Nos are unique so no duplicates should be created.    -   Search Button: When the search button is pressed    -   1) the system should display “Select Item Screen” (see FIG. 4(        c)) for that Mark No.

Using the preferred method and system 10 of materials managementdescribed above the location, status and physical attributes of eachitem of construction material on the site can be updated and tracked atany point during its construction lifecycle. For example, when queriedon a hypothetical material xx01 the system confirms that the item hasbeen ordered, provides a docket number, the date of arrival on site andits precise weight. A user entering the Mark No xx01 into the systemwill see that the material in question has arrived and is located in thelay-down yard at the coordinates 34.45 N and 34.31 E. A query on Mark Noxx03 will reveal that the material has been installed and 90% completed,and so on.

The system is designed to handle large volumes of data and supports manysimultaneous users whilst maintaining a fast response and high degree ofaccuracy. The system provides a variety of custom options that can betailored to the intended end-user application, and it is also very easyto set up and use. It requires minimal IT support, since the PDAsoftware is run from one small file which can be emailed to the clientfor immediate use. A minimum amount of training is required before auser is up and running.

In the case where barcode labels are used for storing machine-readableidentification information the tracking of the material item typicallyends when the item has been installed and construction is finished.However in the case where the machine-readable identificationinformation is stored in an active device such as, for example, a RadioFrequency Identification (RFID) tag, the possibility exists of extendingthe tracking of the item for maintenance purposes. The materialsmanagement system 10 can then be employed for monitoring the ongoingmaintenance of equipment or plant on a construction or mine site. Thismay be particularly advantageous where various types of sensing devicemay be electronically coupled to the RFID tag.

For example, the RFID tag may be electronically coupled to a temperaturesensing device, a corrosion detecting device, a pressure sensor or astrain gauge. Sensing information from the sensing device may be storedin the RFID tag to be collected during periodic maintenance surveys ofthe installation or equipment. The RFID tag may also store the date whenthe last maintenance check was done and when the next maintenance checkis due. A temperature sensor may, for example, be used to monitor thetemperature of a pipe carrying process fluids. Alternatively, or inaddition, a strain gauge may monitor the stresses applied to a beam or awelded joint on the beam. This kind of information is valuable for theongoing safety and maintenance of the installation, and by logging thisinformation electronically in the RFID tag it can be periodicallyaccessed by maintenance workers using a handheld PDA 14. The logged datais then uploaded to the corresponding record for that material item inthe materials database 12, from where it can be analysed and appropriatemaintenance action taken if necessary.

Advantageously a plug-in software module has been designed for thematerials management system that enables it to be integrated withNavisWorks 3D modelling software developed by Autodesk. Each item on theconstruction site is colour-coded in a 3D model of the constructionsite. As the status of the item changes in the database with eachupdate, so the colour of the item in the 3D model also changes to givean immediate visual indication of the current status of the item. Thenumbers of statuses and names of these statuses can be changed accordingto the particular needs of the user.

FIG. 5( a) is a flow chart illustrating the function of the databaseplug-in which operates with the 3D modelling software to provide avisual indication of the current status of each item of material on theconstruction site. At 200 the 3D modelling software loads the databaseplug-in which then provides an operational link with the materialsdatabase 12. Each item in the 3D model of the construction site 70 isgiven a unique id code (corresponding to the item id or barcode appliedto the item of material on the construction site). At step 201 theplug-in compares the unique id of each item in the 3D model with theitem id or barcode in the materials database 12, and when a match isfound it updates the colour of the item in the 3D model at step 202according to the current status of the item in the database.

At step 203 a user can also manually update the colour of an item in the3D model. In that case the plug-in updates the database at 204 based onthe changes made to the 3D model. Typically, an item in the 3D modelcoloured yellow has been received on the building site, but not yetissued for construction. Once it has been issued for construction (asupdated in the database) the colour is changed to green. If an item hasnot yet been installed (according to the database) it is coloured red;however once it has been installed it is coloured blue. Hence by lookingat the 3D model it is possible to see immediately the current status ofeach item on the construction site.

FIG. 5 (b) shows an example of a drawing of a 3D model 70 of aconstruction site in which various items are colour-coded according tothe their current status in the materials database. When an item, forexample a window frame 72 with Mark No: SP-1234, is due on site it maybe shown coloured red in the 3D model. Hence anyone viewing the 3D modelcan immediately see that all the items coloured red in the model are dueon site but have not yet arrived. When an item arrives the materialsdatabase 12 is updated in the manner described above. Fields updated inthe database 12 typically include the Received Date, Received By, DocketNo, Location, and GPS coordinates. If a date is entered in the ReceivedDate field, then the colour of the item in the 3D model is automaticallychanged to yellow.

When the item is issued on site, the following fields are typicallyupdated: Issue Date, Issued By, Location, and GPS coordinates. If a dateis entered in the Issue Date field, then the colour of the item in the3D model is automatically changed to green. This immediately provides avisual indication to a viewer of the 3D model that the window frame 72with Mark No SP-1234 has arrived and been issued on site. When thewindow frame 72 is installed the following fields typically are updatedin the database 12: Install Date, Installed By, Location, and GPScoordinates. Once again, if a date is entered into the Install Datefield, then the colour of the window frame 72 in the 3D model isautomatically changed to blue.

Advantageously the materials management system 10 also includes adocument control database 76 which is integrated with the materialsdatabase 12. A typical process of associating a document that relates toan item recorded in the materials database 12 is illustratedschematically in FIG. 6. When a transmittal 78 is received from aclient, an outside contractor, other staff or a user, it may haveattachments, including drawings, emails, CDs, and/or other documentswhich relate to an item recorded in the database 12. Each document isgiven a barcode or RFID tag which is scanned with the handheld PDA 14and recorded in the document control database 76 on the server. If anRFID tag is used, identification information relating to the document isstored on the RFID tag as well.

A screen is generated by the software for display on the PDA 14 or an adesktop PC 22 connected to the system 10 (see FIG. 1), in whichidentification information relating to the document appears and in whichthe document can be associated by the user with the corresponding itemin the materials database 12 by its Mark No and Item No. In this waydocuments which relate to a piece of equipment or an item in thematerials database 12 can remain associated with that item throughoutits life cycle.

Advantageously the materials management system may also incorporate aprogress control database 80 for monitoring the progress of constructionon a construction site. FIG. 7 is a flow chart illustrating the processof updating a progress control database 80, which is linked to thematerials database 14 of FIG. 1. “Rules of Credit” are created andentered at 128 into the system 10. A “Rule of Credit” is the rule anitem or piece of equipment received on site must follow in order toprogress during the construction phase. Each item recorded in thedatabase 14 is assigned a “Rule of Credit”. Each item received on siteis then progressed according to the applicable “Rule of Credit.”Progress of each item or piece of equipment is recorded and can bemonitored using a special grid, unlike Excel, thus avoiding data entry,etc. Typically electronic tick sheets which are linked to the materialsdatabase may be used to assist in this regard.

A user employs the progress control database (PCDB) 80 to update thematerials database 12 as follows. At 130 the item is located in the PCDBand when found its progress is updated by the user selecting theappropriate tick box/check box or other method of data input at 132. Thesystem then calculates the progress according to the applicable “Rule ofCredit” at 134, and the materials database 12 is updated accordingly at136.

FIG. 8 is a screen shot of a preferred embodiment of the ProgressControl Screen for the progress control database 80. The barcode or RFIDtag on each item is used to monitor the progress and to update thedatabase as described above. In the case of RFID tags, informationconcerning the progress of the item can also be stored on the tag. Ascan be seen in FIG. 8, the Progress Control Screen includes a number ofcolumns relating to each stage in the construction phase of an item orpiece of equipment according to its “Rule of Credit”. In this case, anumber of C3 Columns are listed by item Nos in the far left column. Thefirst item has progressed all the way to completion (100%), through thePreassembly/Installed, Secured/Final Alignment, Grouting (if applicable)and Punchlist Complete stages. The second item in the screen shot is 85%completed; only the final stage (Punchlist Complete) has not beencompleted.

The Progress Control Database 80 thus enables the project manager to seeat a glance at what stage of construction each item in the materialsdatabase 12 is at. Also the Progress Control Database 80 provides areference for the construction managers to control the progress ofconstruction, since an item cannot be progressed in the database unlessit is progressed according to the applicable “Rule of Credit.” TheProgress Control Database 80 thus adds a further useful tool to thematerials management system 10 for managing the movement, installationand commissioning of all material items on a site during all phases ofconstruction.

The materials management system of the invention has particularapplication to a construction site since it is relatively easy to useand can readily be operated from a remote location. In view of the largearea covered by some construction sites such as mine sites themanagement system of the invention is particularly useful in suchapplications.

For example in FIG. 7, the user creates the following rules of credit(Preassembly=30%; Secured 45%; Grouting 10%; Punch list complete 15%).The user then searches for a column tag no/mark no DST-07305200-2. PCDBthen displays all the items/barcodes associated to DST-07305200-2 (FIG.8). User then selects the appropriate tick box for example in item no120608111633 all the tick boxes for preassembly=30%, secured 45%,grouting 10%, punch list complete 15% are selected 132. PCDB thencalculates the progress and in this instance it is 100% 134. Onceconfirmed by the user the system then updates the database 136.

The materials management system of the invention can work in a batchmode when there is no wireless connection or network available. This isideal for remote sites where there is no IT or communicationinfrastructure is available. The user can update the information onmobile computers/PDA/handheld devices and then can upload theinformation using a docking system (see FIG. 9). The materialsmanagement system of the invention can work on sites where intrinsicallysafe environment is required (eg Oil and Gas fields). In this caseintrinsically safe PDAs or mobile devices will be used in the fields andthe system will run in a batch mode (see FIG. 10).

The materials management system of the invention will also work if thereis no identification tag on an item. This is because the system caninterrogate or query the database using the Mark no or Tag no which isstamped on the item. This is ideal for sites where the items orequipments are coming from area (eg overseas) where it is not feasibleto attach a tag to an item.

Now that a preferred embodiment of the system and method of materialsmanagement have been described in detail, it will be apparent that theembodiment provides a number of advantages over the prior art, includingthe following:

-   -   (i) It helps to avoid costly down-times by providing up-to-date        tracking and management of all items of construction material on        a site.    -   (ii) It is easy to use and the handheld PDA facilitates rapid,        real time updating of information in the database.    -   (iii) It is readily scalable to suit any sized project and is        fully compatible with other commonly used in-house software        systems.    -   (iv) It provides increased productivity onsite due to up-to-date        information on material delivery, movement and inventory.    -   (v) It enables increased productivity for procurement staff and        material controllers by minimising the risk of mistakes and        reducing the requirements for double entry of data.    -   (vi) It provides useful plug-in tools to facilitate visual        representation of progress on site using 3D modelling software        and a Progress Control Database

It will be readily apparent to persons skilled in the relevant arts thatvarious modifications and improvements may be made to the foregoingembodiments, in addition to those already described, without departingfrom the basic inventive concepts of the present invention. For example,instead of the MC9090-S PDA a GPS-enabled Blackberry, iPhone or anyWindows mobile base device such as (mate JasJam, could be used as themobile data processing device. Therefore, it will be appreciated thatthe scope of the invention is not limited to the specific embodimentsdescribed and is to be determined from the appended claims.

The claims defining the invention are as follows:
 1. A materialsmanagement system for a site, the system comprising: a materialsdatabase storing information relating to the nature, identity, statusand location of each item of material on the site; a progress controldatabase storing information on changes to be made to each item at thesite as indicated by one of a Rules of Credit assigned to the item, andthe progress control database stores information on a current status ofeach item indicating the last change made to each item at the site asthe item progresses toward completion, wherein the last change isaccording to the one of the Rules of Credit assigned to the item; asoftware module for color-coding each item in a three-dimensional (3D)model of the site, the software module monitoring the materials databaseand the progress control database and, as the current status of an itemchanges in at least one of the materials and progress control databases,changing the color of the item in the 3D model to give a visualindication of the current status of the item; and, a mobile dataprocessing device including a data scanner for scanning machine-readableinformation, including item identification information and informationrelating to the current status of the item, wherein the machine-readableinformation is provided in an identification tag attached to the item,and a GPS receiver operatively connected to the mobile data processingdevice for obtaining the GPS coordinates of the item, the mobile dataprocessing device transmitting the GPS coordinates of the item, theidentification information of the item and the current statusinformation of the item, to at least one of the progress controldatabase and the materials database whereby, in use, the current statusof each item of material on site can be tracked.
 2. A materialsmanagement system for a site as defined in claim 1, wherein the mobiledata processing device is a handheld device.
 3. A materials managementsystem for a site as defined in claim 1, wherein the mobile dataprocessing device is a handheld personal digital assistant (PDA).
 4. Amaterials management system for a site as defined in claim 1, whereinthe mobile data processing device communicates with the materialsdatabase via mobile telephone coverage.
 5. A materials management systemfor a site as defined in claim 1, wherein the data scanner provided inconnection with the mobile data processing device is a barcode scanner.6. A materials management system for a site as defined in claim 1,wherein the data scanner provided in connection with the mobile dataprocessing device is an RFID tag scanner.
 7. A materials managementsystem for a site as defined in claim 1, wherein the GPS receiver isoperatively connected to the mobile data processing device by means of awireless communications link.
 8. A materials management system for asite as defined in claim 1, wherein the GPS receiver is integrated andhardwired into the mobile data processing device.
 9. A materialsmanagement system for a site as defined in claim 1, wherein the datascanner provided in connection with the mobile data processing device iscapable of scanning additional machine-readable information provided inthe identification tag attached to an item of material, such additionalmachine-readable information relating to the ongoing maintenance of theitem.
 10. A materials management system for a site as defined in claim1, wherein the system further comprises one or more sensing devicesprovided in connection with the item of material for sensing a conditionof the item, the sensing device being electronically coupled to theidentification tag, wherein information relating to the condition of theitem can be stored in the identification tag.
 11. A materials managementsystem for a site as defined in claim 1, wherein the identification tagis an RFID tag.
 12. A materials management system for a site as definedin claim 1, wherein the system further comprises a document controldatabase which stores identification information for documentsassociated with one or more of the items of material.
 13. A materialsmanagement system for a site as defined in claim 1, wherein electronictick sheets are linked to the materials database.
 14. A method ofmanaging materials on a site, the method comprising the steps of:applying an identification tag to each item of material on the site, thetag containing machine-readable information including identificationinformation identifying the item of material and information relating tochanges to be made to the item at the site; providing a materialsdatabase for storing information relating to the nature, identity,current status and location of each item of material on the site,wherein the current status indicates the change last made to the item asprescribe in a Rule of Credit assigned to the item; providing a progresscontrol database including Rules of Credit, wherein each of the Rules ofCredit sets forth changes to be made to an item at the site and assignedto the Rule of Credit; changing each of the items at the site inaccordance with the one of the Rules of Credit assigned to the item and,in response to the changing of each item, updating the current status ofthe item to indicate the change made to the item; scanning anidentification tag attached to an item of material on the site to readthe machine-readable information; obtaining current GPS coordinates ofthe item having the attached identification tag; transmitting thecurrent status of the item to at least one of the materials database andthe progress control database, wherein the current status includes thecurrent GPS coordinates of the item, the identification information ofthe item and the updated status of the item; updating information in atleast one of the materials database and the progress control databasewith the received current status of each item to indicate the changes tothe item having the attached identification tag in the progress controldatabase and materials database based on the current GPS coordinates ofeach item, the identification information of the item and the updatedstatus of the item; providing a three dimensional (3D) model of thesite; and changing the color of a display image of the item having theattached identification tag shown in the 3D model based on the currentstatus of the item according to the updated information in at least oneof the progress control database and materials database whereby, in use,the current status of each item of material on site is indicated in thedisplay image.
 15. A method of managing materials on a site as definedin claim 14, wherein the method comprises the further steps of: storingadditional machine-readable information in the identification tag,including information relating to the ongoing maintenance of the item inthe identification tag; transmitting the additional information to thematerials database; and, updating a maintenance log for the item in thedatabase whereby, in use, the ongoing maintenance of each item ofmaterial on site can be tracked.
 16. A method of managing materials on asite as defined in claim 15, wherein the additional information storedin the identification tag also includes information relating to theprogress of the item in the various stages of construction.
 17. A methodof updating a materials database for a materials management system for asite, the method comprising the steps of: providing a progress controldatabase associated with the materials database, wherein the materialsdatabase stores material item records regarding the identity, currentstatus and location of items and the progress control database storesinformation change records indicating changes made to each itemassociated with a project to be completed at the site; creating Rules ofCredit each prescribing changes to be made to corresponding item forwhich information is stored in the progress control database; assigningeach of the Rules of Credit to a corresponding item for whichinformation is stored in the materials database; retrieving a materialitem record stored in the materials database upon receivingidentification information scanned from an identification tag attachedto an item of material, wherein the retrieved material item recordincludes a current status indicating a last change made to the item atthe site as prescribed by the one of the Rules of Credit assigned to theitem; tracking the current status of the item in the progress controldatabase according to the assigned Rule of Credit, wherein the trackingincludes updating the current status of the item in response to a changemade to the item at the site; generating and displaying an update screenfor the material item record wherein, in use, an operator inputs updateinformation for the material item record, including the current GPScoordinates of the item of material and the current status of the item;updating the material item record in the materials database with theupdate information; providing a three dimensional (3D) model of a sitewhere the item of material is to be installed; and, changing the colorof the item shown in the 3D model based on the current status of theitem according to the update information in the updated material itemrecord of the materials database.
 18. A method of updating a materialsdatabase as defined in claim 17, wherein the method of updating amaterials database further comprises, in the case where a material itementry cannot be retrieved from the materials database based on thescanned identification information, the steps of: generating anddisplaying a search screen wherein, is use, an operator can specify aMark No for the material item; searching the materials database for allitems having the specified Mark No; displaying the search list for allitems with the specified Mark No wherein, in use, an operator can selectan item from the search list; and, retrieving a material item recordstored in the materials database corresponding to the item selected bythe operator.
 19. A method of updating a materials database as definedin claim 18, wherein the method of updating a materials database furthercomprises, in the case where no items having the specified Mark No canbe retrieved from the materials database or where none of the items withthe specified Mark No corresponds to the material item, the steps of:generating and displaying a screen that enables the operator to create anew record in the materials database for the specified Mark No ormaterial item; and, storing the new record in the materials database.20. A method of updating a materials database as defined in claim 17,further comprising the steps of: monitoring the changes made to eachitem in the progress control database; and, using electronic tick sheetswhich are linked to the materials database to assist in recording thechanges made to each item.
 21. A materials management system for aconstruction site, the system comprising: a materials database forstoring information relating to the nature, identity, status andlocation of each item of material on the construction site; a progresscontrol database in which the progress at the construction site ofchanges to each item in the materials database is controlled accordingto a Rule of Credit assigned to the item; updating the current statusindicating the last change made to each item at the site as prescribedby the Rule of Credit assigned to the item; a software module forcolor-coding each item on the site in a three dimensional (3D) model ofthe construction site, the software module monitoring the materialsdatabase and, as the current status of an item changes in the materialsdatabase, changing the color of the item in the 3D model to give avisual indication of the current status of the item; and, a mobile dataprocessing device having a data scanner for scanning machine-readableinformation, including information identifying the item, the currentstatus of the item, provided in an identification tag attached to one ofthe items of material, and a GPS receiver operatively connected to themobile data processing device for obtaining the GPS coordinates of theitem, the mobile data processing device transmitting the GPScoordinates, the identification information, the current statusinformation to the progress control database and the materials databasewhereby, in use, the current status and the location of each item ofmaterial at the construction site can be tracked.